Nanocrystalline zirconia and methods of processing thereof

ABSTRACT

Zirconia dental ceramics exhibiting opalescence and having a grain size in the range of 10 nm to 300 nm, a density of at least 99.5% of theoretical density, a visible light transmittance at or higher than 45% at 560 nm, and a strength of at least 800 MPa.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a divisional application ofU.S. application Ser. No. 15/866,909, filed on Jan. 10, 2018, whichclaims priority to and is a divisional application of U.S. applicationSer. No. 14/891,756, filed on Nov. 17, 2015, now U.S. Pat. No.10,004,668, which is the National Stage application of InternationalPatent Application No. PCT/US2014/042140 filed on Jun. 12, 2014, whichclaims priority to U.S. Application No. 61/840,055, filed Jun. 27, 2013,entitled Nanocrystalline Zirconia And Methods Of Processing Thereof, allthe disclosures of which are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

The present invention is directed to dental restorations comprisingnanozirconia and methods of processing thereof, and more particularly tonanozirconia dental ceramics combining translucency that matchesglass-ceramics, opalescence mimicking natural dentition and highstrength characteristic of tetragonal zirconia.

BACKGROUND

Currently, the best commercially available full contour (monolithic)zirconia dental ceramic materials are aesthetically inferior to lithiumdisilicate or leucite-based glass ceramic materials like IPS e.max orIPS Empress due to lower translucency and lack of opalescence. Betterlight transmittance and opalescence are required to better mimic naturaldentition. Human enamel has varying “anisotropic” translucency whichintroduces many optical effects that are difficult to replicate withceramic material. Opalescence is one optical characteristic of naturalenamel that can create a highly complex visual display. To date, onlyglass ceramic materials come close to duplicating such opticalcomplexity of natural dentition including opalescence. At the same timeglass-ceramic materials are not as strong as zirconia materials hencelimiting their clinical use to single- and multi-unit restorations andcases without bruxism.

U.S. Pat. No. 8,309,015, which is hereby incorporated by reference inits entirety, is directed to a method of processing tetragonalnanozirconia with grain sizes under 100 nm. The sintered body is claimedto only contain pores smaller than about 25 nm. The method is lackingbulk shape consolidation technology and does not address, mention ordiscuss opalescence. Rather, the requirements set forth in the patentand claims include the diameter of any pores which are present in thetranslucent zirconia sintered body to be not more than about 25 nm,which as believed, would preclude this material from being in thedesired opalescent range as taught in the present invention and also isunrealistic for any practical bulk shape consolidation technologyyielding dental articles via pressureless sintering.

U.S. Pat. No. 8,598,058, which is hereby incorporated by reference inits entirety, is directed to a method of processing nanozirconiaarticles with grain sizes under 200 nm and pore size under 50 nmcomprising from about 0.5% to about 5.0% lanthanum oxide claimed to beessential to achieve the claimed properties. Again this patent does notaddress, mention or discuss opalescence despite showing sintered bodiesilluminated with incident light whereby opalescence would be obvious ifpresent.

U.S. Pat. Nos. 7,655,586 and 7,806,694, both hereby incorporated byreference in their entirety, are directed to a dental article andfabrication methods comprising: a single component yttria-stabilizedtetragonal zirconia ceramic material having grains of average grain sizeexceeding 100 nanometers and not exceeding about 400 nanometers, whereinthe ceramic material is fabricated of particulate material consistingessentially of ceramic crystallites with an average size of less thanabout 20 nm; wherein the particulate material is sintered withoutapplication of external pressure at a temperature less than about 1300°C. to a full density wherein the final pore size does not exceed thesize of the ceramic crystallite size; and wherein the ceramic materialexhibits at least 30% relative transmission of visible light whenmeasured through a thickness of about 0.3 to about 0.5 mm. Again therequirements set forth in the patents and claims limit the diameter ofpores and achievable grain size distributions which are present in thetranslucent zirconia sintered body, which as believed would precludethis material from being opalescent.

The following patents and published applications, directed to zirconiaceramics or processing methods, are hereby incorporated by reference intheir entirety: U.S. Pat. Nos. 6,787,080, 7,655,586, 7,806,694 U.S. Pat.Nos. 7,833,621, 7,674,523, 7,429,422, 7,241,437, 6,376,590, 6,869,501,8,298,329, 7,989,504, 8,425,809, 8,216,439, 8,309,015, 7,538,055,4,758,541, US20110027742, US20120058883, US20100003630, US20090274993,US20090294357, US20090115084, US20110230340, US20090004098,US20100075170, US20040222098, and US20130313738. Among them U.S. Pat.No. 8,298,329 and US20130313738 describe translucent nano-crystallinedental ceramics and a process of fabrication of the same by slip-castingor powder compaction.

The following publications are directed to processing and properties ofzirconia or transparent alumina ceramics.

Adam, J., et al. “Milling of Zirconia Nanoparticles in a Stirred MediaMill”, J. Am. Ceram. Soc., 91 [9] 2836-2843 (2008)

Alaniz, J. E., et al. “Optical Properties of Transparent NanocrystallineYttria Stabilized Zirconia”, Opt. Mater., 32, 62-68 (2009)

Anselmi-Tamburini, etc al. “Transparent Nanometric Cubic and TetragonalZirconia Obtained by High-Pressure Pulsed Electric Current Sintering”,Adv. Funct. Mater. 17, 3267-3273 (2007)

Apetz, R., et al. “Transparent Alumina: A Light Scattering Model”, J.Am. Ceram. Soc., 86 [3], 480-486 (2003)

Binner, J., et al. “Processing of Bulk Nanostructured Ceramics”, J. Eur.Ceram. Soc. 28, 1329-1339 (2008)

Binner, J. et al. “Compositional Effects in Nanostructured YttriaPartially Stabilized Zirconia” Int. J. Appl. Ceram. Tec., 8, 766-782(2011)

Casolco, S. R. et al. “Transparent/translucent polycrystallinenanostructured yttria stabilized zirconia with varying colors” ScriptaMater. 58 [6], 516-519 (2007)

Garcia, et al. “Structural, Electronic, and Optical Properties of ZrO2from Ab Initio Calculations”, J. Appl. Phys., 100 [1], 104103 (2006)

Klimke, et al. “Transparent Tetragonal Yttria-Stabilized ZirconiaCeramics” J. Am. Ceram. Soc., 94 [6] 1850-1858 (2011)

Knapp, K. “Understanding Zirconia Crown Esthetics and OpticalProperties”, Inclusive Magazine, (2011)

Rignanese, et al, “First-principles Study of the Dynamical andDielectric Properties of Tetragonal Zirconia” Phys. Rev. B, 64 [13],134301 (2001)

Srdic, V. V., et al. “Sintering Behavior of Nanocrystalline ZirconiaPrepared by Chemical Vapor Synthesis” J. Am. Ceram. Soc. 83 [4], 729-736(2000)

Srdic, V. V., et al. “Sintering Behavior of Nanocrystalline ZirconiaDoped with Alumina Prepared by Chemical Vapor Synthesis” J. Am. Ceram.Soc. 83 [8], 1853-1860 (2000)

Trunec, et al. “Compaction and Presureless Sintering of ZirconiaNanoparticles” J. Am. Ceram. Soc. 90 [9] 2735-2740 (2007)

Vladimir V. Srdic', Markus Winterer, and Horst Hahn. “Sintering Behaviorof Nanocrystalline Zirconia Prepared by Chemical Vapor Synthesis”. J.Am. Ceram. Soc., 83 [4] 729-36 (2000)

Most or all of the above-listed patents and publications describe avariety of properties of tetragonal nanozirconia materials andprocessing methods thereof. All of these sources appear to describesintering with application of external pressure such as HIP or SPS.

Light transmission at about 550-560 nm is commonly accepted to comparelight transmittance of dental materials, especially dental zirconiamaterials, which is related to the color resolution/sensitivity ofphotopic vision of human eyes. In humans, photopic vision allows colorperception, mediated by cone cells in the retina. The human eye usesthree types of cones to sense light in three bands of color. Thebiological pigments of the cones have maximum absorption values atwavelengths of about 420 nm (bluish-violet), 534 nm (Bluish-Green), and564 nm (Yellowish-Green). Their sensitivity ranges overlap to providevision throughout the visible spectrum from about 400 nm to about 700nm. Colors are perceived when the cones are stimulated, and the colorperceived depends on how much each type of cone is stimulated. The eyeis most sensitive to green light (555 nm) because green stimulates twoof the three kinds of cones almost equally; hence light transmission at560 nm is used as a basis for characterization of highly translucentzirconia materials of the present invention.

Opalescence is one of the important optical characteristics of naturaldentition that is critical to replicate in aesthetic dental restorativematerial in order to fabricate life-like dental restorations. Thisesthetic requirement is often referred to as the “vitality of arestoration”. It is a well-known optical effect resulting in a bluishappearance in reflected color and an orange/brown appearance intransmitted color. The opalescent property is generally associated withscattering of the shorter wavelengths of the visible spectrum, byinclusions of the second phase(s) having a different refractive indexfrom the matrix phase. In human teeth, opalescence of natural enamel isrelated to light scattering and dispersion produced by complex spatialorganization of enamel's elemental constituents—hydroxyapatitenanocrystals. Hydroxyapatite crystallites forming human enamel arearranged in bundles or sheets forming rods (bundles) and interrods(sheets), which are organized in a honeycomb-like structure. The averagecrystal size is 160 nm long and 20-40 nm wide. As light travels throughthe enamel, the rods scatter and transmit the shorter wavelength light,rendering the enamel opalescent.

The degree of opalescence can be quantified by a colorimetricspectrophotometry measurement with a CIE standard. For example, Lee etal. (see references below) use “Opalescence Parameter” (OP) as a measureof opalescence. Kobashigawa et. al. (U.S. Pat. No. 6,232,367) use thesame basic formula, but termed it “Chromaticity Difference”. Theopalescence parameter (OP or “Chromaticity Difference”) is calculatedaccording to the following formula:

OP=[(CIEa _(T*)−CIEa _(R*))²+(CIEb _(T*)−CIEb _(R*))²]^(1/2),

wherein (CIEa_(T*)−CIEa_(R*)) is the difference between transmission andreflectance modes in red-green coordinate a*; (CIEb_(T*)−CIEb_(R*)) isthe difference between transmission and reflectance modes in yellow-bluecolor coordinate b*. Using this formula, OP of the commerciallyavailable current state of the art “translucent” zirconia is calculatedto be in the range from about 5 to about 7. These commercial materialsare clearly not opalescent. According to literature data, it is believedthat materials with low OP values are not opalescent. The measured OPrange for clearly opalescent human enamel was 19.8-27.6. According toKobashigawa, for matching the vitality of natural teeth, the OP valueshould be at least 9, and preferably higher, so that the opalescenceeffect is clearly observed. On the other hand it is not useful to matchhigh OP values of human enamel “just by numbers” since the restorationwill not blend well with the adjacent teeth in the patient's mouth.

The following publications are directed to mechanisms of opalescence innatural or synthetic materials.

Cho, M.-S. et al. “Opalescence of all-ceramic core and veneermaterials”, Dental Materials, 25, 695-702, (2009)

Egen, M. et al. “Artificial Opals as Effect Pigments in Clear-Coatings”,Macromol. Mater. Eng. 289, 158-163, (2004)

Lee, Y.-K., et al. “Measurement of Opalescence of Resin Composites”,Dental Materials 21, 1068-1074, (2005)

Lee, Y.-K., et al. “Changes in Opalescence and Fluorescence Propertiesof Resin Composites after Accelerated Aging”, Dental Materials 22,653-660, (2006)

Lee, Y.-K., “Influence of Scattering/Absorption Characteristics on theColor of Resin Composites” Dental Materials 23, 124-131, (2007)

Lee, Y.-K., “Measurement of Opalescence of Tooth Enamel”, Journal ofDentistry 35, 690-694, (2007)

Kobashigawa, A. I. et al., “Opalescent Fillers for Dental RestorativeComposites”, U.S. Pat. No. 6,232,367 B1, (2001)

Peelen. J. G. J. et al. “Light Scattering by Pores in PolycrystallineMaterials: Transmission Properties of Alumina”, Journal of AppliedPhysics, 45, 216-220, (1974)

Primus, C. M., et al. “Opalescence of Dental Porcelain Enamels”Quintessence International, 33, 439-449, (2002)

Yu, B., et al. “Difference in Opalescence of Restorative Materials bythe Illuminant”, Dental Materials 25, 1014-1021, (2009)

White et al., Biological Organization of Hydroxyapatite Crystallitesinto a Fibrous Continuum Toughens and Controls Anisotropy in HumanEnamel, J Dent Res 80(1): 321-326, (2001).

It would be extremely beneficial to have high translucency of glassceramics combined with high strength of tetragonal zirconia andopalescence mimicking natural dentition in the same dental restorativematerial sinterable below 1200° C., which can be processed into a fullcontour zirconia restoration using conventional techniques and equipmentsuch as dental CAD/CAM systems, dental pressing furnaces and dentalfurnaces. Other techniques and equipment successfully used in otherareas of technology for mass production of near-net shaped parts andcomponents can be also used.

SUMMARY

These and other features are achieved by nanozirconia bodies of thepresent invention. In one embodiment, certain ranges of processingconditions are utilized to produce nanozirconia bodies that areopalescent in green, brown (pre-sintered) and fully dense condition asshown in FIG. 2. Opalescent nanozirconia bodies can be also nearlytransparent or highly translucent in all stages of processing (visiblelight transmittance at or higher than 45% and preferably higher than 50%at 560 nm for 1 mm samples) and result in fully dense tetragonalzirconia bodies (at least 99.5% or higher density and preferably ≥99.9%dense) that in addition to high light transmittance also comprise highstrength (at least 800 MPa or higher strength and preferably ≥1200 MPastrength) and sinterability at temperatures below 1200° C. inconventional dental furnaces which is especially important for dentalrestorative applications.

FIG. 1 shows the spectral (wavelength) dependence of light transmittancewithin visible light range of 400-700 nm for a variety of dentalmaterials including the current state of the art commercial“translucent” zirconia brands fabricated from Zpex™ and Zpex™ Smilepowders made by Tosoh (Japan). Light transmittance of Zpex™ and Zpex™Smile made materials measured at 560 nm, the wavelength of visible lightof aforementioned “maximal physiological significance,” is 39% and 46%,respectfully for 1 mm samples. The difference in light transmittancebetween Zpex™ and Zpex™ Smile samples is related to their Yttria (Y₂O₃)content and resulting phase composition: while Zpex™-made zirconiacomprising 3 mole % of Y₂O₃ is tetragonal, Zpex Smile made zirconia(˜5.3 mole % of Y₂O₃) is comprising both tetragonal and cubic phases,hence it is more translucent but only half as strong as tetragonalzirconia (˜1200 MPa vs˜600 MPa, respectfully). Both materials as well asother commercial zirconia materials are clearly not opalescent.

By comparing curves presented in FIG. 1 it becomes apparent thatopalescent nanozirconia materials of the present invention have steeperspectral transmittance curves as measured in transmittance mode by aconventional visible light spectrophotometer equipped with anintegrating sphere. This is consistent with the fact that beingopalescent, nanozirconia materials of the present invention scatter bluelight, i.e. shorter wavelengths, preferentially, while allowingyellowish red light, i.e. longer wavelengths, to transmit through withlimited scattering. Thus, it allows us to define their advantageouslight transmittance properties as being higher than 45% and preferablyhigher than 50% in the whole spectral range of 560 nm to 700 nm forunshaded or “naturally colored” nanozirconia and higher than 35% andpreferably higher than 40% in the whole spectral range of 560 nm to 700nm for shaded nanozirconia intentionally doped with coloring ions suchas Fe, Cr, Ni, Co, Er, Mn and other ions/oxides listed in U.S. Pat. Nos.6,713,421 and 8,178,012 which are hereby incorporated by reference intheir entirety. Typically, light transmittance of shaded zirconia is5-10% lower than light transmittance of unshaded or “naturally colored”zirconia.

In tetragonal nanozirconia of the present invention, it is believed thatopalescence comes from the interaction of visible light with thespecific crystal structure and grain/pore size distributions. Inparticular, we speculate that scattering mainly occurs due to theexistence of residual pores and/or grain size dependent birefringenceand the associated differences in refractive index between pores andtetragonal zirconia matrix or between different crystallographicorientations in a crystal lattice of individual nanozirconiacrystallites. In this complex optical phenomenon or combination ofoptical phenomena resulting in opalescence, both total porosity and poresize distribution will affect the pore related scattering in all stagesof nanozirconia processing from green to brown to sintered bodies; whilecontribution of birefringence intrinsic to tetragonal zirconia isdependent on the grain size distribution in partially or fully sinteredbodies. Normally the pore and grain sizes in well-formed nanozirconiacompacts are of the same scale and increasing concurrently withdensification and grain growth. The desired level of opalescence existsonly for specific combination of porosity, and pore/grain sizedistributions. Selective scattering of only the short wavelengths ofvisible light is the key to achieve a combination of optical opalescenceand a high level of translucence. It can be speculated that one of theapplicable scattering models is Rayleigh scattering, in which the sizeof scattering species are much smaller than the incident wavelength, theintensity of scattering (I) is strongly dependent on wavelength, and thescattered intensity on both forward and backward directions are equalfor a specific wavelength. According to Rayleigh scattering theory, thefact that scattering cross-section σ_(s) is proportional to λ⁻⁴, where λis the wavelength of the incident light explains why the shorter (blue)wavelengths are scattered more strongly than longer (red) wavelengths.For example, the same nanoscale scattering center/site would scatter awavelength at 430 nm (in the blue range) by a factor of 6 times moreefficiently compared to a wavelength of 680 nm (in the red range). As aresult, an observer will find that the samples appear bluish in colorwhen observing from the same side of the light source while yellowishand reddish when observing from the opposite side of the light source.This unique characteristic of nanozirconia materials of the presentinvention occurs only for specific processing methods and startingmaterials described below resulting in such specific grain and pore sizedistributions during a transition from a transparent to a translucentstage within the overall grain size range of 10 nm to 300 nm and finalpore size mostly larger than 25 nm, and preferably larger than 30 nmwith total porosity being less than 0.5% and preferably less than 0.1%(in the fully dense nanozirconia bodies). The average grain size intranslucent opalescent zirconia of the present invention as measuredaccording to ASTM E112-12 test method is from 40 nm to 150 nm,preferably from 50 to 100 nm, and most preferably from 50 to 80 nm.

The materials of the present invention are especially useful for fullcontour restorations combining the strength of zirconia with aestheticsof glass-ceramics benchmarks.

In various embodiments, dental restorations comprising opalescentnanozirconia can be shaped by milling, injection molding,electrophoretic deposition, gel-casting etc.

Opalescent nanozirconia dental restorations of the present inventioncomprise the following key features:

Opalescent with OP values above 9 and preferably above 12.

Nearly transparent or highly translucent in shaded or unshaded (natural)condition: Light transmittance of at least 45% and preferably higherthan 50% at a wavelength of 560 nm or even in the whole spectral rangeof 560 nm to 700 nm for unshaded or “naturally colored” nanozirconia for1 mm samples; and higher than 35% and preferably higher than 40% at 560nm or even in the whole spectral range of 560 nm to 700 nm for shadednanozirconia intentionally doped with coloring ions for 1 mm samples.

Predominantly tetragonal, i.e., major phase is tetragonal zirconia (lessthan 10% cubic) and preferably YTZP, i.e., Yttria Stabilized TetragonalZirconia Polycrystal with Y₂O₃ content within the range from 0 to 3 mole%.

Grain size within overall range from 10 nm to 300 nm, or 20 nm to 250nm, in fully sintered condition as confirmed by analysis of fracturesurfaces (see representative fracture surface in FIGS. 11A, 11B and11C).

The average grain size in translucent opalescent zirconia of the presentinvention as measured according to ASTM E112 (or EN 623-3) test methodis from 40 nm to 150 nm, preferably from 50 to 100 nm, and mostpreferably from 50 to 80 nm.

Pore size mostly larger than 25 nm, preferably 30 nm when density ishigher than 99.5%. Most preferably that porosity is less than 0.1%(density ≥99.9% of theoretical density) for maximal visible lighttransmittance.

Strong—ISO 6872 flexural strength at least 800 MPa or higher, andpreferably ≥1200 MPa strength; and most preferably ≥2 GPa strength.

Sinterable at temperatures <1200° C. using conventional dental furnacesor microwave dental furnaces.

Shaped by CAD/CAM, EPD, LPIM, dental heat-pressing (like glass ceramicingots) similar to LPIM and gel-casting using RP molds.

The zirconia may include a stabilizing additive selected from Y, Ce, Mg,or mixtures thereof, or other known stabilizing additive.

The numbers and ranges in the specification and claims can cover valuesobtained by applying the regular rules of rounding and/or up to +1-5%.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will be more fully understood andappreciated by the following Detailed Description in conjunction withthe accompanying drawings, in which:

FIG. 1 shows the spectral (wavelength) dependence of light transmittancewithin visible light range of 400-700 nm for a variety of dentalmaterials including the current state of the art commercial“translucent” zirconia brands fabricated from Zpex™ and Zpex™ Smilepowders made by Tosoh (Japan).

FIG. 2 shows transition of tetragonal nanozirconia material of thisinvention from nearly transparent green to translucent fully densestage.

FIGS. 3A and 3B compare light transmittance and opalescence of thenanozirconia materials of the present invention in green, brown andfully dense condition to commercial dental zirconia materials in a fullydense condition.

FIG. 4 shows a generic flowchart of the processing method of the presentinvention.

FIG. 5 shows a flowchart of an embodiment of the process in accordancewith the present invention.

FIG. 6 shows a veneer made from fully dense nanozirconia of the presentinvention exhibiting clearly visible opalescence.

FIG. 7 shows a microstructure of 99.9% dense opalescent nanozirconiabody with average grain size of 136 nm sintered in a conventional dentalfurnace in accordance with the present invention as described in Example1A.

FIG. 8 shows a microstructure of 99.9% dense opalescent nanozirconiabody with average grain size of 112 nm sintered in a conventional dentalfurnace in accordance with the present invention as described in Example1C.

FIG. 9 shows a microstructure of 99.9% dense opalescent nanozirconiabody with average grain size of 108 nm sintered in conventional dentalfurnace in accordance with the present invention as described in Example2A with a pore of at least 35 nm marked in the SEM micrograph.

FIG. 10 shows a microstructure of 99.9% dense opalescent nanozirconiabody with average grain size of 91 nm sintered in a hybrid microwavefurnace in accordance with the present invention as described in Example4B.

FIGS. 11A, 11B and 11C show fracture surfaces of some of nanozirconiamaterials of the present invention at various magnificationsillustrating typical grain size range and occasional nano-pores withsizes ranging from 30 nm to 100 nm.

FIG. 12 shows the transition from transparent to opaque nanozirconiabodies made from organic solvent based suspension of ZrO₂ nanoparticleswithout Y2O3 or any other tetragonal phase stabilizer.

FIG. 13A shows particle size distribution of nanozirconia suspensionconcentrated to ˜17 vol % from 4.5 vol % suspension prior to (1) andafter attrition-milling (2).

FIG. 13B shows particle size of as-received ˜17 vol % nano-zirconiasuspension prior to (1) and after attrition-milling (2).

DETAILED DESCRIPTION

It was surprisingly found that within a certain range of processingconditions and starting particle sizes the resulting nanozirconia bodiesare opalescent in green, brown (or pre-sintered) and, most importantly,in fully dense condition. Opalescent nanozirconia bodies can be alsonearly transparent or highly translucent in all stages of the processingand result in fully dense bodies (at ≥99.5% dense) that in addition tohigh light transmittance also comprise high strength (≥800 MPa and evenin excess of 2 GPa) and sinterable at temperatures below 1200° C. inconventional dental furnaces which is especially important for dentalrestorative applications. The materials of the present invention areespecially useful for full contour restorations combining strength ofzirconia with aesthetics of glass-ceramics benchmarks. Dentalrestorations comprising opalescent nanozirconia can be shaped bymachining/milling, injection molding, dental heat-pressing,electrophoretic deposition, gel-casting and other dental technologies ortechnologies used in industry at large for shaping high-performanceceramics. Specifically, CAD/CAM blanks can be formed by slip-casting(coarser nanoparticulates only), centrifugal casting, drop-casting,injection molding, filter-pressing and electrophoretic deposition (EPD).

It is specific pore size distribution and/or grain size distributionthat are believed to render predominantly single phase tetragonalzirconia of this invention both highly translucent and opalescent. Wecan speculate that in order to generate opalescence in a fully densenanozirconia, at least a portion, preferably a major portion ofscattering species (e.g. tetragonal grains with anisotropic refractiveindex and occasional nano-pores) form some kind of “optical sub-lattice”and have a characteristic size or diameter within a specific, fairlynarrow range. Within this range the scattering species are large enoughto cause adequate scattering of blue light yet small enough to not causemuch scattering of yellow-red light, which can be explained by theRayleigh scattering model. Rayleigh approximation is generallyapplicable to scattering species much less than wavelength of light orspecifically for birefringence effects when tetragonal grain size is atleast an order of magnitude less than wavelength of visible light. Miemodel is not restricted by grain size. Both models coincide when thegrain size is less than 50 nm. Maximized opalescence will be achievedwhen present scattering species are about or just below the sizestransitional between the Rayleigh and the Mie models (where they startto diverge). It can be further speculated that once their size exceedsthe transitional range, the opalescence effect will largely disappear asthe less wavelength-dependent Mie scattering mechanism is operational.This upper size limit for opalescence is dictated by differences inrefractive index between the pores and the tetragonal zirconia matrixand/or between different crystallographic orientations in a crystallattice of individual nanozirconia crystallites. In addition, anothercritical factor that imposes an upper limit on the size of scatteringspecies (mostly grains since residual porosity is minimal) is hightranslucence required for aesthetic dental ceramics. Also shading ofnanozirconia invariably further lowers overall visible lighttransmittance imposing further constraints on grain size distribution toachieve the same light transmittance. Typically light transmittance ofshaded zirconia is about 5-10% lower than light transmittance ofunshaded or “naturally colored” zirconia.

Opalescence and other physical properties of the materials of thepresent invention can be quantified within the following ranges:

Property Broad Range Preferred Range Phase composition and Predominantlytetragonal YTZP (yttria-stabilized chemistry zirconia with less than 15%tetragonal zirconia monoclinic and cubic phase polycrystal) with 0-3 mol% combined. Y₂O₃ Opalescence Visually opalescent with OP valuespreferably above OP values above 9 12 Nearly transparent or Lighttransmittance higher Preferably light highly translucent in than 45% atwavelength of transmittance higher than shaded or unshaded 560 nm oreven in the whole 50% at wavelength of 560 (natural) condition spectralrange of 560 nm to nm or even in the whole 700 nm for unshaded orspectral range of 560 nm to “naturally colored” 700 nm for unshaded ornanozirconia; and higher “naturally colored” than 35% at 560 nm ornanozirconia; and higher even in the whole spectral than 40% at 560 nmor range of 560 nm to 700 nm even in the whole spectral for shadednanozirconia range of 560 nm to 700 nm intentionally doped with forshaded nanozirconia coloring ions (to match intentionally doped withinternal or external shade coloring ions (to match standardsapproximating internal or external shade tooth colors) standardsapproximating tooth colors). Overall grain size range At least 95% ofgrains by All grains are from 10 nm in fully sintered volume are from 10nm to to 300 nm in size (or condition 300 nm in size (or diameter),diameter) or 20 nm to 250 nm in size (diameter) Average grain size From40 nm to 150 nm, Preferably from 50 to 100 measured according to nm, andmost preferably ASTM E112 (or EN from 50 to 80 nm. 623-3) test methodDensity/residual porosity Pore size mostly larger than Most preferablythat in fully sintered 30 nm wherein density is porosity is less than0.1% condition higher than 99.5%. (density ≥99.9% of theoreticaldensity) Flexural strength ISO 6872 flexural strength Preferably ≥1200MPa at least 800 MPa or higher flexural strength; and most preferably ≥2GPa flexural strength Sinterable at Sinterable at temperatures <1200°Sinterable at temperatures ≤1150° temperatures <1200° C. C. usingconventional dental furnaces C. using conventional dental furnaceswithout application of or microwave dental furnaces or microwave dentalfurnaces external pressure (pressureless sintering) Shaped by CAD/CAM,Preferred way is machining of partially sintered blanks EPD, LPIM,dental heat- formed by slip-casting (limited use - for coarser pressing(like glass nanoparticulates only), centrifugal casting, drop-casting,ceramic ingots) similar to gel-casting, injection molding,filter-pressing and LPIM and gel-casting electrophoretic deposition(EPD) using RP molds

To further illustrate the advantageous properties listed in the tableabove, FIGS. 3A and 3B compare light transmittance and opalescence ofthe nanozirconia materials of the present invention to commercial dentalzirconia materials. In one preferred embodiment, the processschematically shown in FIG. 4 will result in green or pre-sintered(brown) millable blanks that can be further processed into dentalarticles such as dental restorations (blanks, full-contour FPDs (fixedpartial dentures), bridges, implant bridges, multi-unit frameworks,abutments, crowns, partial crowns, veneers, inlays, onlays, orthodonticretainers, space maintainers, tooth replacement appliances, splints,dentures, posts, teeth, jackets, facings, facets, implants, cylinders,and connectors) using commercially available dental CAD/CAM systems. Inthe alternative embodiments, dental articles can be formed directly fromsuspension by EPD, gel-casting in the enlarged molds formed byrapid-prototyping (RP). In another alternative embodiment,nanoparticulates of the present invention can be provided as feed-stockfor injection molding. In the latter case the enlarged molds forlow-pressure injection molding (LPIM) can be formed by RP. RP is usefulto form molds that are enlarged to compensate for isotropic sinteringshrinkage of the materials of the present invention when they aresintered from green or pre-sintered state to a full density.

It is important to note that highly translucent tetragonal nanozirconiabodies were produced from two types of nanozirconia suspensions spanningthe wide range of processing scenarios as shown in the flow chart inFIG. 4. Organic based Pixelligent (Pixeligent Technologies, Baltimore,Md.) nanozirconia suspensions (0% Y₂O₃) with solid loading of ˜14 vol %and aqueous based MEL (MEL Chemicals, Flemington, N.J.) suspension of3Y-TZP (3 mole % Y₂O₃) with solid loading of ˜5 vol %.

EXAMPLES

The non-limiting examples illustrating some of the embodiments andfeatures of the present invention are further elucidated in FIGS. 6-13.Commercially available nanozirconia suspensions were received fromvarious manufacturers. The most useful suspensions preferably comprisewell-dispersed nanoparticles with average primary particle size of ≤20nm and preferably ≤15 nm. In certain cases nanosuspensions comprisingpartially agglomerated and/or associated nanoparticles can be also usedwith average particulate size up to 40-80 nm. The latter will requireattrition milling to deagglomerate and commune nanoparticles to therequired size range. The starting zirconia concentration is usually low,e.g. 5 vol %, but concentrated suspensions are also available from somemanufacturers (see FIG. 13B). These concentrated suspensions may containproprietary dispersants. The liquid medium of the suspension ispreferably water, and can also be organic solvents, e.g. ethanol,methanol, toluene, dimethylformamide, etc. or mixtures of such. Thesuspension was stabilized by addition of dispersants and adjustment ofpH. A dispersant used to stabilize nanosuspensions in the examples belowwas one of the following: Poly(ethyleneimine),2-[2-(2-Methoxyethoxy)ethoxy] acetic acid, or 2-(2-Methoxyethoxy)aceticacid. The amount of dispersants by weight of solid zirconia was no morethan 10% (e.g., from 0.5 wt % up to 10 wt %). The pH values ofsuspension were in the range of 2 to 13. Centrifuging and/or attritionmilling may be applied to remove and/or break theagglomerated/aggregated portion of solids prior to or after stabilizingthe suspensions. In some cases, binders may be added to the suspensionin order to enhance the strength of the cast. The suspensions were thenconcentrated by evaporating off the solvents at elevated temperaturewith or without vacuum assistance. After concentration, the suspensionwill be above 10 vol %, e.g. preferably at least 14 vol %, preferably16%, most preferably 18 vol %, and up to 50 vol % depending onrequirements of forming methods. After concentration, the viscosity(measured at 25° C.) of concentrated suspensions prior to casting waswell below 100 cP and in most cases below 30 cP, most preferablyviscosity should be at or below 15 cP as this level of viscosityproduced best casting results. Attrition milling may also be used duringor after the concentrating process primarily to break down agglomeratesand aggregates and sometimes to reduce particle size.

The concentrated zirconia suspensions with desired solid loadings werethen used to cast zirconia green bodies. The forming methods include:slip-casting, gel-casting, electrophoretic deposition, drop-casting,filter pressing, injection molding, and centrifugal casting as well asother known applicable forming methods. After casting, the green bodieswere dried in a temperature, pressure, and humidity controlledenvironment to ensure forming crack-free articles. The drying conditionsare usually dictated by the dimensions of the articles: e.g. thickerarticles require longer drying time to prevent cracking. After drying,green bodies were at least 35%, preferably 45%, more preferably over 50%of theoretical density. Dried green bodies were burnt out to remove theorganic species including dispersants, binders, and any other additives.The peak burn-out temperature was no higher than 700° C., preferablyfrom 500° C. to 600° C. Optional pre-sintering can be carried out attemperatures up to 850° C. After burn out, the articles, so-called“brown” bodies, were then sintered at temperatures lower than 1200° C.to reach full density. Sintering can be carried out in dental furnaces,traditional high temperature furnaces, or hybrid microwave furnaces.Density of the sintered articles was measured by the Archimedes methodusing water as the immersion medium. Relative density, calculated usinga theoretical density value of 6.08 g/cm³, is usually ≥99.5% in fullysintered articles in the current invention.

The fully sintered samples were then ground to 1.0 mm for opticalproperty measurement. Transmittance and reflectance were measured by aKonica Minolta Spectrophotometer CM-3610d, according to the CIELAB colorscale in the reflectance and transmittance mode relative to the standardilluminant D65. The aperture diameter was 11 mm for reflectancemeasurement, and 20 mm for transmittance measurement. Measurements wererepeated five times for each specimen and the values were averaged toget the final reading. The transmittance of green bodies through 1 mmthickness was at least 50% at 560 nm, and was at least 45% for the brownbodies.

Opalescence parameter was calculated as:

OP=[(CIEa _(T*)−CIEa _(R*))²+(CIEb _(T*)−CIEb _(R*))²]^(1/2),

whereas (CIEa_(T*)−CIEa_(R*)) is the difference between transmission andreflectance modes in red-green coordinate, a* of CIE L*a*b* color space;(CIEb_(T*)−CIEb_(R*)) is the difference between transmission andreflectance modes in yellow-blue color coordinate, b* of CIE L*a*b*color space.

The biaxial flexural strength measurements were performed by an MTS QTest machine on disk samples with a thickness of 1.2±0.2 mm according toISO6872-2008. Sintered samples were also polished, thermally etched andimaged under Zeiss Sigma Field Emission scanning electron microscope(SEM). Average grain size was calculated by the intercept methodaccording to ASTM E112-12.

Example 1

2 kg of 5 vol % aqueous suspension of yttria (3 mol %) stabilizedzirconia nanoparticulate was received from Mel Chemicals (Flemington,N.J.). This suspension was de-agglomerated by centrifuging at 7000 rpmfor 40 minutes. The suspension was then stabilized by adding 2%dispersants by weight of solid zirconia. The pH of such stabilizedsuspension was 2.5. This suspension was concentrated from 5 vol % to 18vol % of solid loading with an Ika RV10 vacuum evaporator at 40° C. and40 mbar for about 4 hours. Cylindrical PTFE molds of from 18 mm to 32 mmin diameter and 10 mm in height were prepared, and the zirconiasuspension was poured into the molds. 5 to 15 g of slurry was applied toeach mold depending on the desired final thickness. Then molds withsuspension were put into an environmental chamber for curing and drying.For the first 72˜120 hours, the humidity was above 85% and temperaturewas about 25° C. The drying time was determined by the thickness of thesamples. The thicker samples took a longer time to dry withoutgenerating cracks. Then environmental humidity decreased gradually toabout 20%, where final water content in the green bodies reached lessthan 4 wt %. The as-formed green bodies were ˜49% of theoreticaldensity. Transmittance was 58% for 2 mm thick green body at 560 nm.Dried green bodies were burned out by heating at a rate of 0.5° C./minto 550° C. and holding for 2 hours. The brown bodies, of 1.8 mm thick,had transmittance of 49% at 560 nm. The brown bodies were then sinteredin a dental furnace (Programat P500, Ivoclar Vivadent AG.) at a ramprate of 10° C./min to 1150° C., held for 2 hours, and then coolednaturally in air. After sintering, the disk samples were from 12 to 23mm in diameter and 1.5 mm in thickness, with relative density of 99.98%.Probably due to contamination by Fe, Ni or Cr from the stainless steelequipment used in manufacturing of the starting nanozirconiasuspensions, all fully sintered samples in Example 1 to Example 6appeared tinted, i.e., noticeably yellow-brownish in color with a huethat resembles the natural tooth color.

The samples were then ground down to thickness of 1.0 mm fortransmittance and reflectance measurements. The transmittance of such“tinted” samples was 37.7%, and opalescence factor was 13.6. An SEMimage of a polished and thermally etched cross-section is shown in FIG.7, and the average grain size is 136 nm. The biaxial flexural strengthis 2108±386 MPa.

In the following parallel experiments, all processing conditionsremained identical, except that the binder burn out and/or sinteringconditions were modified.

For Example 1B, sintering was carried out at 1125° C. for 2 hours.

In example 1C to 1F, a 2-step sintering method was adapted, by heatingthe samples to a higher temperature (e.g. 1125° C., 1150° C.) for veryshort time (e.g. 6 seconds), and then quickly dropping to lowertemperature (e.g. 1075° C., 1050° C.) and holding for a prolonged periodof time.

In Example 1C, the sample was heated from room temperature to 1125° C.at 10° C./min rate and held at 1125° C. for 6 seconds; then it wascooled down to 1075° C. quickly and held at 1075° C. for 20 hours. AnSEM image of a polished and thermally etched cross-section is shown inFIG. 8, and the average grain size is 112 nm. Biaxial flexural strengthis 1983±356 MPa.

In example 1D, the sample was heated from room temperature to 1150° C.at 10° C./min rate and held at 1150° C. for 6 seconds; then it wascooled down to 1075° C. quickly and held at 1075° C. for 20 hours.Biaxial flexural strength is 2087±454 MPa.

In example 1E, the sample was heated from room temperature to 1125° C.at 10° C./min rate and held at 1125° C. for 6 seconds; then it wascooled down to 1075° C. quickly and held at 1075° C. for 15 hours.

In example 1F, the sample was heated from room temperature to 1125° C.at 10° C./min rate and held at 1125° C. for 10 seconds; then it wascooled down to 1075° C. quickly and held at 1075° C. for 20 hours.

In another parallel experiment, the binder burn-out conditions werealtered. Example 1G was processed at all identical conditions as Example1C, except the peak burn out temperature was raised from 550° C. to 700°C.

Results on density, biaxial flexural strength, grain size, lighttransmittance, and opalescence measurements are summarized in Table 1below.

TABLE 1 Biaxial Solid Flexural Average Light Loading Relative StrengthGrain size Transmission Opalescence Example Dispersant (vol %) SinteringDensity % (MPa) (nm) @560 nm Color Factor 1A 2% 18 1150/2 h 99.98 2108 ±386 136 38 yellow- 14 brownish, tooth like hue 1B 2% 18 1125/2 h 99.96 —114 38 yellow- 14 brownish, tooth like hue 1C 2% 18 1125/6 s- 99.95 1983± 356 112 40 yellow- 15 1075/20 h brownish, tooth like hue 1D 2% 181150/6 s- 99.90 2087 ± 454 — 39 yellow- — 1075/20 h brownish, tooth likehue 1E 2% 18 1125/6 s- 99.91 — — 39 yellow- 14 1075/15 h brownish, toothlike hue 1F 2% 18 1125/10 s- 99.92 — — 38 yellow- 15 1075/20 h brownish,tooth like hue 1G 2% 18 1125/6 s- 99.92 — — 39 yellow- 13 1075/20 hbrownish, tooth like hue 2A 2% 18 1100/4 h 99.94 — 108 — yellow- —brownish, tooth like hue 2B 2% 18 1125/2 h 99.94 — — 38 yellow- —brownish, tooth like hue 2C 2% 18 1100/3 h 99.96 — — 39 yellow- 14brownish, tooth like hue 2D (2 + 3)% 18 1125/2 h 99.90 — — — yellow- —brownish, tooth like hue 2E 4% 18 1125/2 h 99.92 — 119 — yellow- —brownish, tooth like hue 3A 2% 14 1150/2 h 99.92 — 131 37 yellow- —brownish, tooth like hue 3B 2% 14 1125/6 s- 99.91 — 107 39 yellow- —1075/20 h brownish, tooth like hue 4A 2% 18 1125C/2 h 99.86 — — —yellow- — brownish, tooth like hue 4B 2% 18 1125/6 s- 99.92 — 91 —yellow- — 1075/20 h brownish, tooth like hue 5 2% 18 1150/2 h 99.50 — —— yellow- — brownish, tooth like hue 6 2% 18 1150/2 h 99.90 — — —yellow- — brownish, tooth like hue

Example 2

The suspension preparation and concentration steps were identical toExample 1A. After concentration and prior to casting, an addition step,attrition milling, was carried out using Netzsch MiniCer attrition mill.The concentrated suspension was milled with 200, 100, or 50 μm of yttriastabilized zirconia beads at 3000 rpm rotation speed. After attritionmilling, the suspension was cast into PTFE molds, dried, and burned outin the same procedures as in Example 1A.

For Example 2A, the attrition milling time was 1 hours, and the brownbodies were sintered at 1100° C. for 4 hours.

For Example 2B, the attrition milling time was 1.5 hours, and the brownbodies were sintered at 1125° C. for 2 hours.

For Example 2C, the attrition milling time was 1.5 hours, and the brownbodies were sintered at 1100° C. for 3 hours.

For Example 2D, after original attrition milling for 1.5 hours at 3000rpm in the attrition mill, an additional 3 wt % (according to the weightof zirconia) of additives was added to the suspension. Attrition millingcontinued another 1 hour. The suspension was cast into molds, dried, andburned out in same procedures as in Example 1A. The sample was thensintered at 1125° C. for 2 hours.

For Example 2E, the suspension and preparation steps were identical toExample 1A except that 4 wt % of dispersant was used. Afterconcentration, attrition milling was performed for 3 hours. The sampleswere sintered at 1125° C. for 2 hours.

Density, optical properties, and grain size were measured and reportedin Table 1. SEM image of Example 2A is shown in FIG. 9, where a ˜35 nmdiameter pore was observed. All samples are visually opalescent.

Example 3

In the stabilization step, a different dispersant of 2 wt % was used incomparison to Example 1A, and the suspension was concentrated to 14 vol%. After concentration, the suspension was cast into the molds. Dryingand burning out were carried out at identical procedures as Example 1A.

For Example 3A, the sample was heated to 1150° C. at 10° C./min and heldfor 2 hours.

For Example 3B, the sample was heated to 1125° C. with 10° C./min rateand held at 1125° C. for 10 seconds; then it was cooled down to 1075° C.quickly and held at 1075° C. for 20 hours.

Density, optical properties, and grain size were measured and reportedin Table 1. All samples were visually opalescent.

Example 4

The suspension stabilization, concentration, and processing conditionsare identical as Example 1A except that the brown bodies were sinteredin a microwave assisted high temperature furnace, MRF 16/22, Carbolite,Hope Valley, UK.

In Example 4A, the sample was heated at 10° C./min to 1125° C. in IRsensor controlled mode, with microwave on after 700° C. in auto mode.Then the sample dwelled at 1125° C. under 500 W microwave for 2 hours.The sample was cooled down naturally.

In Example 4B, the sample was heated at 10° C./min to 1125° C. in IRsensor controlled mode for 6s, and then held at 1075° C. for 20 h.During heating, the microwave started at 700° C. in auto mode, andduring dwelling the microwave was manually set at 200 W.

Density and grain size were measured and reported in Table 1. FIG. 10shows the microstructure of Example 4B with average grain size of 91 nmand density of 99.92%. All such sintered samples are visuallyopalescent.

Example 5

500 g of 5 vol % aqueous suspension of 3 mol % yttria stabilizedzirconia nanoparticulate was received from Mel Chemicals (Flemington,N.J.). This suspension was stabilized by addition of 3 wt % dispersantsby weight of solid zirconia. The stabilized suspension was concentratedfrom 5 vol % to 18 vol % in a glass beaker by heating while stirring at50° C. for 14 hours in a water bath with a hot plate. Slip casting wascarried out using plaster molds, prepared by casting cylinders of 32 mmin diameter, and 30 mm in height with USG No. 1 Pottery Plaster. Thecylinders were wrapped with plastic paper for holding the slurriesbefore consolidation. 5 to 15 g of concentrated slurry was poured intoeach mold depending on the desired final thickness. After the slurry wasconsolidated, the plastic paper was removed, and the consolidated partswere removed from the plaster and put into a drying box for curing anddrying under controlled humidity (identical to Example 1A). Afterdrying, the green bodies were burned out at a rate of 0.5° C./min to700° C. and held for 2 hours. Brown bodies were sintered in a dentalfurnace (Programat P500, Ivoclar Vivadent AG.) by heating at a rate of10° C./min to 1150° C. and held for 2 hours.

The relative density of the so-formed articles was measured to be99.50%. All such formed articles were visually opalescent.

Example 6

The suspension was stabilized, concentrated and de-agglomerated in theidentical steps as illustrated in Example 1A. 40 ml suspension was thentransferred to a PTFE centrifuge vessel and centrifuged at 11000 rpm for40 min by Legend XT Centrifuge, ThermoScientific. Afterwards, thesupernatant was carefully removed by pipetting. The dense bottom partstayed in the PTFE vessel and was subjected to drying for 15 days. Afterthe part was dried completely, it was removed from the mold and burnedout at 700° C. for 2 hours. The so-formed brown body was ground into arealistically shaped veneer with an enlargement factor of 1.25 andsintered. Sintering was carried out in Programat P500 dental furnace at1150° C. for 2 hours, and the density was measured to be 99.90%. Theso-formed veneer was polished to a glossy finish with thickness between0.3-1.5 mm. It appears opalescent as shown in FIG. 6.

Example 7

An organic solvent based nanozirconia suspension (0% Y₂O₃) was receivedfrom Pixelligent Technologies (Baltimore, Md.). The concentration ofas-received suspension was 14.0 vol % with an average particle size of 5to 8 nm in a toluene solution. This suspension was concentrated byslowly evaporating the solvent under ambient conditions in a PTFE tube.After the part was completely dried, it was then removed from the tubeand subjected to burn out at 550° C. for 2 hours. Both green and brownbodies were transparent. Sintering was carried out at temperatures from900° C. to 1100° C. for 1 hour. The phase and grain size was measuredand calculated by grazing incidence X-ray diffraction and SEM, and theresults are listed in Table 2. Some opalescence can only be observed insamples sintered at 1000° C. and 1050° C. There is no “tint” observedfor any of the sintered bodies; they appeared basically colorless. Thehighest density for sintered bodies was 98.3%, and all samples showedsevere cracking after heat treatment. Results on visual appearance,density, grain size and phase composition are listed in Table 2 below.

TABLE 2 Sintering temp ° C. 900 950 1000 1050 1100 Appearance (see FIG.12) Translucent Translucent “Window” “Window” with some with someTransparent Transparent opalescence opalescence Opaque Density (%) n/a98.3 ± 0.2 97.8 ± 0.2 95.5 ± 0.1 NA Grain size na na 35 40 90 estimatedfrom SEM (nm) Grain Size 7 13 18 22 18 from XRD (nm) Phases Tetragonalphase Monoclinic phase > 90

Although preferred embodiments have been depicted and described indetail herein, it will be apparent to those skilled in the relevant artthat various modifications, additions, substitutions, and the like canbe made without departing from the spirit of the invention and these aretherefore considered to be within the scope of the invention as definedin the claims which follow.

What is claimed is:
 1. A method of manufacturing an opalescent zirconiadental article comprising: providing a well-dispersed suspension ofzirconia nanoparticles having an average particle size of less than 20nm; forming the suspension into a shape of the dental article or a blankto produce a wet zirconia green body; drying the wet green body in acontrolled humidity atmosphere to produce a zirconia green body; heatingthe zirconia green body to provide a zirconia brown body, wherein thezirconia green body is shaped before heating, or the zirconia brown bodyis shaped after heating; sintering the zirconia brown body at atemperature below or equal to 1200° C. to provide an opalescent zirconiasintered body; wherein a resulting grain size of the sintered dentalarticle is between 10 and 300 nm and an average grain size is between 40nm and 150 nm.
 2. The method of manufacturing an opalescent zirconiadental article of claim 1, wherein the heating step comprises heating upthe zirconia green body at a temperature in the range of from 500 to700° C. to remove any organic residuals to form a zirconia brown body.3. The method of manufacturing an opalescent zirconia dental article ofclaim 1, further comprising pre-sintering the brown body at atemperature up to 850° C. prior to sintering.
 4. The method ofmanufacturing an opalescent zirconia dental article of claim 3, whereinthe pre-sintering step and the heating step can be combined into onestep.
 5. The method of manufacturing an opalescent zirconia dentalarticle of claim 1, wherein the step of forming the suspension into ashape comprises an isotropically enlarged, uniform shape.
 6. The methodof manufacturing an opalescent zirconia dental article of claim 1,wherein the dried green body or brown body is shaped by CAD/CAM, LPIM ordental heat-pressing.
 7. The method of manufacturing an opalescentzirconia dental article of claim 1, wherein the zirconia nanoparticleshave an average particle size less than 15 nm.
 8. The method ofmanufacturing an opalescent zirconia dental article of claim 1, whereinthe well-dispersed suspension of zirconia nanoparticles comprises asolids volume percent of particles in the range of 10 to 50 vol. %. 9.The method of manufacturing an opalescent zirconia dental article ofclaim 1, wherein the well-dispersed suspension further comprises adispersant in an amount of not more than 10 wt. % of total solids in thesuspension.
 10. The method of manufacturing an opalescent zirconiadental article of claim 9, wherein the dispersant comprisespoly(ethyleneimine), 2-[2-(2-methoxyethoxy)ethoxy] acetic acid, or2-(2-methoxyethoxy)acetic acid.
 11. The method of manufacturing anopalescent zirconia dental article of claim 1, wherein thewell-dispersed suspension is further de-agglomerated by attritionmilling.
 12. The method of manufacturing an opalescent zirconia dentalarticle of claim 11, wherein the suspension is further refined bycentrifuging instead of, prior to, or after attrition milling.
 13. Themethod of manufacturing an opalescent zirconia dental article of claim1, wherein sintering is conducted in conventional dental furnaces, hightemperature furnaces, microwave dental furnaces or hybrid furnaces. 14.The method of manufacturing an opalescent zirconia dental article ofclaim 1, wherein the sintering temperature is below or equal to 1150° C.15. The method of manufacturing an opalescent zirconia dental article ofclaim 1, wherein the sintering temperature is below or equal to 1125° C.16. The method of manufacturing an opalescent zirconia dental article ofclaim 1, wherein forming the suspension into blanks or the dentalarticle comprises centrifugal casting, drop-casting, gel-casting,injection molding, slip casting, filter-pressing and/or electrophoreticdeposition (EPD).
 17. The method of manufacturing an opalescent zirconiadental article of claim 1, wherein the well-dispersed suspensionscomprises a liquid medium selected from the group consisting of water,ethanol, methanol, toluene, dimethylformamide, or mixtures thereof. 18.A method of manufacturing an opalescent zirconia dental articlecomprising: providing a well-dispersed suspension of zirconiananoparticles having an average particle size of less than 20 nm;forming the suspension into a shape of the dental article or a blank toproduce a wet zirconia green body; drying the wet green body in acontrolled humidity atmosphere to produce a zirconia green body; heatingthe zirconia green body to provide a zirconia brown body, wherein thezirconia green body is shaped before heating, or the zirconia brown bodyis shaped after heating; sintering the zirconia brown body at atemperature below or equal to 1200° C. to provide an opalescent zirconiasintered body; wherein the majority of the pores are greater than 25 nmat a density of at least 99.5% theoretical density.
 19. The method ofmanufacturing a zirconia dental article of claim 18, wherein themajority of the pores are greater than 30 nm at a density of at least99.5% theoretical density.
 20. A suspension for forming a zirconiadental article comprising: well-dispersed zirconia nanoparticles havingan average particle size of less than 20 nm; a solids volume percent ofparticles in the range of 10 to 50 vol. %; wherein the resulting grainsize of the of the zirconia dental article is between 10 and 300 nm andan average grain size is between 40 nm and 150 nm; and wherein thezirconia dental article is opalescent.
 21. The suspension for forming azirconia dental article of claim 20, wherein the solids volume percentof particles is at least 14 vol %.
 22. The suspension for forming azirconia dental article of claim 20, wherein the solids volume percentof particles is at least 16 vol %.
 23. The suspension for forming azirconia dental article of claim 20, wherein the solids volume percentof particles is at least 18 vol %.
 24. The suspension for forming azirconia dental article of claim 20, having a viscosity of less than 100cP at 25° C.
 25. The suspension for forming a zirconia dental article ofclaim 24, having a viscosity of less than 30 cP at 25° C.
 26. Thesuspension for forming a zirconia dental article of claim 25, having aviscosity of less than 15 cP at 25° C.
 27. The suspension for forming azirconia dental article of claim 23, wherein the well-dispersedsuspension is further de-agglomerated by attrition milling.
 28. A greenbody for forming a zirconia dental article comprising: zirconiananoparticles having an average particle size of less than 20 nm;wherein the resulting grain size of the of the zirconia dental articleis between 10 and 300 nm and average grain size is between 40 nm and 150nm; and wherein the zirconia dental article is opalescent.
 29. The greenbody of claim 28, wherein the green body comprises a transmittance of58% for a 2 mm thickness at 560 nm.
 30. A method of manufacturing anopalescent zirconia dental article comprising providing a zirconia greenblank having zirconia nanoparticles having an average particle size ofless than 20 nm; shaping the zirconia green blank by CAD/CAM, LPIM, ordental heat-pressing, or heating the zirconia green blank to form abrown blank and shaping the brown blank by CAD/CAM machining; sinteringthe shaped zirconia green blank or brown blank at a temperature below orequal to 1200° C. to provide an opalescent zirconia sintered body;wherein the resulting grain size of the sintered dental article isbetween 10 and 300 nm and average grain size is between 40 nm and 150nm.
 31. The method of manufacturing an opalescent zirconia dentalarticle of claim 30, wherein the step of heating the zirconia greenblank to form a brown blank comprises pre-sintering.